Methods and Systems for Synthesizing Iron-Based Materials and Sequestering Carbon Dioxide

ABSTRACT

Methods and systems for sequestering carbon dioxide and generating hydrogen are disclosed. In some embodiments, the methods include the following: dissolving an iron based material that includes a carbonate-forming element into a solution including the carbonate-forming element and iron; increasing a pH of the solution to cause precipitation of iron oxide from the solution thereby generating a first source of Fe 2 O 3 ; reacting the carbonate-forming element in the solution with a first source of carbon dioxide to produce a carbonate thereby sequestering the carbon dioxide; oxidizing the first source of Fe 2 O 3  with a carbonaceous fuel thereby generating a second source of carbon dioxide and iron; and oxidizing the iron with steam thereby generating hydrogen and an iron oxide. Some embodiments include producing iron-based catalysts.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of copending U.S. patent application Ser. No. 13/319,831, filed Nov. 10, 2011, which is a national stage patent application of PCT/US2010/034921, filed May 14, 2010, which claims the benefit of U.S. Provisional Application No. 61/178,272, filed May 14, 2009, all of which are incorporated by reference as if disclosed herein in their entireties.

BACKGROUND

Since the industrial revolution, the amount of CO₂ in the atmosphere has risen from 280 ppm in 1800 to 370 ppm in 2000, mainly due to the consumption of fossil fuels. More than half of the energy used in the United States comes from the use of coal, and it is mostly used to generate electricity. Unfortunately, CO₂ is one of the greenhouse gases considered to be responsible for global warming. Moreover, the increased atmospheric CO₂ concentration will acidify the ocean and will change the chemistry of the surface ocean, leading to a potentially detrimental impact on the ecosystem. In order to meet the ever-increasing global energy demands, while stabilizing the atmospheric CO₂ level, current carbon emissions should be significantly reduced.

There have been significant research and development activities in the area of carbon capture and storage (CCS), including a number of integrated technologies (e.g., chemical looping processes) to combine CO₂ capture with electricity/chemical/fuel production. Chemical looping processes involve a sorbent, typically a metal, or more likely a low oxidation state metal oxide that can be oxidized in air. The oxide is reduced by carbonaceous fuels in a subsequent step. A variation of this approach oxidizes the metal not in air but in a chemical reaction with steam to produce a pure stream of H₂. The chemical looping processes also allow the inherent generation of the sequestration-ready CO₂ stream at higher pressures.

Once captured, CO₂ can be stored via geological sequestration, ocean disposal, mineral carbonation, and biological fixation. The mineral sequestration scheme is particularly attractive, since this process converts CO₂ into thermodynamically stable carbonates via the reaction of CO₂ with widely available non-carbonate minerals, such as serpentine and olivine. Therefore, the mineral sequestration process eliminates the risk of accidental CO₂ releases. The reaction underlining mineral carbonation mimics natural chemical transformations of CO₂, such as the weathering of rocks. The main challenges of this storage method have been the slow dissolution kinetics and large energy requirement associated with the mineral processing.

SUMMARY

The previously developed pH swing carbon mineral sequestration immobilizes the gaseous CO₂ into a thermodynamically stable solid, MgCO₃, using Mg-bearing minerals such as serpentine. This mineral carbonation technology is particularly promising since it generates value-added solid products: high surface area silica, iron oxide, and magnesium carbonate, while providing a safe and permanent storage option for CO₂. By carefully controlling the pH of the system, these solids products can be produced with high purity. The disclosed subject matter focuses on the synthesis of iron oxide particles as a chemical looping sorbent in order to achieve the integration between carbon capture and storage technologies. The synthesized iron-based chemical looping sorbent has been found to be as effective as commercially available iron oxide nanoparticles at converting syngas/carbonaceous fuel into high purity H₂, while producing a sequestration-ready CO₂ stream.

The disclosed subject matter utilizes the iron component of magnesium-bearing minerals, e.g., olivine and serpentine, during carbon mineral sequestration. These minerals often contain 5-10 percent by weight of iron, and the recovery and utilization of iron during the mineral processing increases the economic feasibility of carbon mineral sequestration technology. Among many applications of iron-based materials, the disclosed subject matter focuses on the synthesis of iron-based chemical looping sorbents, which can be used for carbon dioxide capture and hydrogen production, as well as the syntheses of iron-based catalysts to be used in the production of synthetic liquid fuels and hydrogen from carbonaceous materials including coal, biomass, and municipal solid wastes.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings show embodiments of the disclosed subject matter for the purpose of illustrating the invention. However, it should be understood that the present application is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

FIG. 1 is a chart of a method according to some embodiments of the disclosed subject matter; and

FIG. 2 is a schematic diagram of a system according to some embodiments of the disclosed subject matter.

DETAILED DESCRIPTION

Some embodiments of the disclosed subject matter include methods and systems for sequestering carbon dioxide and generating hydrogen. Methods and systems according to the disclosed subject matter include combining pH swing carbon sequestration processes with chemical looping processes. pH swing processes are employed, which can sequestrate CO₂ while generating solid products: high surface area silica; iron oxide; and magnesium carbonate. Iron-based chemical looping sorbents are synthesized during the pH swing carbon mineral sequestration process. Thus, two CCS technologies are integrated. Processes including carbon mineral sequestration are used to generate a supply of Fe₂O₃, which is used by chemical looping processes for H₂ production. The CO₂ produced during chemical looping processes is then sequestered via mineral carbonation.

As shown in equations [1] and [2], pH swing processes are used to both consume a first source of carbon dioxide to produce carbonated minerals and thus sequester the carbon dioxide and also generate iron-based chemical looping sorbents from minerals, respectively:

1/3(Mg,Fe)₃Si₂O₅(OH)₄+CO2=MgCO₃+Fe+2/3SiO₂+2/3H₂O;   [1]

and

Fe+NH₄OH→Fe(OH)₃ (and ultimately Fe₂O₃)   [2]

As shown in equations [3] and [4], the iron-based chemical looping sorbents are then reduced via oxidation with a carbonaceous fuel to generate a second source of carbon dioxide for consumption in the pH swing processes. Finally, as shown in equations [5] and [6], the iron-based chemical looping sorbents are regenerated via oxidation with steam to generate hydrogen:

3CO+Fe2O3→3CO2+2Fe;   [3]

3H2+Fe2O3→3H20+2Fe;   [4]

3Fe₄H₂O→Fe₃O₄+4H₂;   [5]

and

4Fe₃O₄+O₂→6Fe₂O (ultimately to Fe₂O₃).   [6]

Referring now to FIG. 1, some embodiments include a method 100 of sequestering carbon dioxide and generating hydrogen. At 102, an iron-based material such as a magnesium or calcium-bearing mineral or other carbonate-forming element or industrial wastes containing iron and a carbonate-forming element such as calcium or magnesium is dissolved to form a solution including a carbonate-forming element, e.g., magnesium and/or calcium, and iron. Magnesium-bearing minerals, e.g. olivine and serpentine, often contain 510 percent by weight of iron.

At 104, a chelating agent that targets magnesium, calcium, and iron is added to the solution before increasing a pH of the solution. The chelating agent is selected so as to be effective at leaching out iron content from the solution while allowing fast precipitation of iron oxide during the pH swing processes. Examples of chelating agents include acetic acid, citric acid, iminodiacetic acid, oxalic acid, phosphoric acid, gluconic acid, ascorbic acid, phthalic acid, a salt thereof, and a combination thereof. Citric acid has been found to provide higher dissolution as compared other chelating agents.

At 106, a pH of the solution is increased to cause precipitation of iron oxide from the solution thereby generating a first source of Fe₂O₃. In some embodiments, precipitation of iron oxide is conducted in the presence of support materials such as commercially available Fe₂O₃ particles. The support materials can be commercially available materials or high surface area silica produced during dissolution of minerals and/or wastes during method 100.

At 108, the carbonate-forming element, e.g., magnesium or calcium, in the solution is reacted with a first source of carbon dioxide to produce a carbonate, e.g., magnesium or calcium carbonate, thereby sequestering the carbon dioxide. In some embodiments, the first source of carbon dioxide is anthropogenic produced, e.g., emissions from coal-burning power plants and other man-made sources of carbon dioxide.

At 110, the first source of Fe₂O₃ is oxidized with a carbonaceous fuel thereby generating a second source of carbon dioxide and iron. The second source of carbon dioxide can then be utilized in step 108 to produce magnesium carbonate thereby sequestering the carbon dioxide. In some embodiments, the carbonaceous fuel includes gaseous fuels such as synthetic gas (carbon monoxide and hydrogen) and methane. In some embodiments, the carbonaceous fuel includes solid fuels including coal, biomass, and municipal solid wastes.

At 112, the iron is oxidized with steam thereby generating hydrogen and an iron oxide. At 114, the iron oxide is fully oxidized with oxygen thereby generating a second source of Fe₂O₃, which can be reacted with the carbonaceous fuel in 110 to generate additional carbon dioxide and iron.

Although not illustrated in FIG. 1, in some embodiments, iron-based catalysts, e.g., iron oxide, are produced. The produced iron oxide can also be used as catalysts for various industrial processes such as Fischer-Tropsch, water-gas-shift, and biomass conversion processes. These catalysts are currently produced using pure systems but can be produced utilizing methods and systems according to the disclosed subject matter from the waste stream of the carbon mineral sequestration process.

Referring now to FIG. 2, some embodiments of the disclosed subject matter include a system 200 for sequestering carbon dioxide and generating hydrogen. System 200 includes a mineral and waste carbonation module 202 and a chemical looping module 204.

Mineral carbonation module 202 produces iron-based chemical looping sorbents 206 from minerals and industrial wastes 208 using pH swing processes. Iron-based chemical looping sorbents 206 include iron oxides such as Fe₂O₃ or similar. Minerals and industrial wastes 208 are carbonate-forming minerals and wastes including carbonate-forming minerals, e.g., magnesium and calcium-bearing minerals that include iron 210. The pH swing processes also consume a first source of carbon dioxide 212 to produce carbonated minerals 214 such as magnesium or calcium carbonate or similar. In some embodiments, the pH swing processes include the use of a chelating agent 216 to facilitate the extraction of iron 210 from minerals or industrial wastes 208.

In some embodiments, chemical looping module 204 includes a fuel reactor 218 and a hydrogen production reactor 220. In fuel reactor 218, chemical looping processes are utilized to reduce the iron-based chemical looping sorbents 206 via oxidation with a carbonaceous fuel 222 to generate a second source of carbon dioxide 224 for consumption by the pH swing processes in mineral carbonation module 202 and iron 226 (Fe, FeO). In hydrogen production reactor 220, iron-based chemical looping sorbents 206 are regenerated by reducing iron 226 via oxidation with steam 228 to generate hydrogen 230.

In some embodiments, system 200 includes a module for producing iron-based catalysts, e.g., iron oxide. The iron-based catalysts can be used for various industrial processes including Fischer-Tropsch synthesis, water-gas-shift reactions, and biomass conversion.

Methods and systems according to the disclosed subject matter offer benefits and advantages over known technologies. Technology according to the disclosed subject matter can be used for carbon dioxide capture and mineral sequestration, while also being used for hydrogen production.

Synthesized iron-based catalysts can be used in the production of synthetic liquid fuels and/or hydrogen from carbonaceous materials including coal, biomass, and municipal solid wastes. Synthesized iron oxide can also directly be used in the steel industry once it is recovered.

Technology according to the disclosed subject matter ties carbon storage technology with carbon capture technology as well as other sustainable energy conversion systems to improve the overall life cycle of carbon management technologies.

By controlling the pH of the system, technology according to the disclosed subject matter can be used to generate solid products from the mineral carbonation process: SiO₂-rich solids; iron oxide; and MgCO₃*3H₂O. The iron oxide and MgCO₃ produced would be highly pure.

Although the disclosed subject matter has been described and illustrated with respect to embodiments thereof, it should be understood by those skilled in the art that features of the disclosed embodiments can be combined, rearranged, etc., to produce additional embodiments within the scope of the invention, and that various other changes, omissions, and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. 

What is claimed is:
 1. A method of sequestering carbon dioxide, said method comprising: producing iron-based sorbents and a carbonate forming material from minerals comprising iron; consuming a first source of carbon dioxide to produce carbonated minerals from the carbonate forming material; reducing the iron-based sorbents with a carbonaceous fuel to generate a second source of carbon dioxide; and regenerating said iron-based sorbents that have been reduced via oxidation with steam.
 2. The method according to claim 1, wherein the minerals comprising iron include calcium-bearing minerals, magnesium-bearing minerals, and industrial wastes.
 3. The method according to claim 1, further comprising producing iron-based catalysts including Fischer Tropsch catalysts, water-gas-shift catalysts, and biomass conversion catalysts.
 4. The method according to claim 3, wherein said iron-based catalysts and iron-based sorbents include iron oxides such as Fe₂O₃.
 5. The method of according to claim 1, further comprising isolating the iron-based sorbents from the carbonate forming material via a pH swing process.
 6. The method according to claim 1, further comprising the step of consuming the second source of carbon dioxide using the carbonate forming material.
 7. The method according to claim 1, wherein the step of regenerating said iron-based sorbents further includes the step of generating hydrogen.
 8. A method of sequestering carbon dioxide and generating hydrogen, said method comprising: dissolving a material that includes a carbonate-forming element and iron with a chelating agent into a solution; increasing a pH of said solution to cause precipitation of a first source of iron oxide from said solution; reacting said carbonate-forming element with a first source of carbon dioxide; reducing said first source of iron oxide with a carbonaceous fuel thereby generating a second source of carbon dioxide and reduced iron; and oxidizing said reduced iron with steam thereby generating hydrogen and a second source of iron oxide.
 9. The method according to claim 8, further comprising: producing iron-based catalysts including Fischer Tropsch catalysts, water-gas-shift catalysts, and biomass conversion catalysts.
 10. The method according to claim 8, wherein said material is selected from the group consisting of: calcium-bearing minerals, magnesium-bearing minerals, and industrial wastes containing iron and carbonate-forming elements including magnesium and calcium.
 11. The method according to claim 8, wherein said carbonate forming element is selected from the group consisting of: magnesium, calcium, and a combination thereof.
 12. The method according to claim 8, further comprising: oxidizing said second source of iron oxide with oxygen thereby generating a source of fully oxidized Fe₂O₃.
 13. The method according to claim 10, wherein the chelating agents are added to said solution before increasing a pH of said solution to dissolve said minerals or said wastes and target Ma, Ca and Fe and include acetic acid, citric acid, iminodiacetic acid, oxalic acid, phosphoric acid, gluconic acid, ascorbic acid, phthalic acid, a salt thereof, and a combination thereof.
 14. The method according to claim 8, further comprising: reacting said carbonate-forming element in said solution with said second source of carbon dioxide to produce a carbonate thereby sequestering said carbon dioxide.
 15. The method according to claim 8, further comprising: reacting said second source of iron oxide with said carbonaceous fuel.
 16. The method according to claim 8, wherein said carbonaceous fuel includes gaseous fuels including carbon monoxide and hydrogen and methane.
 17. The method according to claim 8, wherein precipitation of the first source of iron oxide is conducted in the presence of support materials such as provided Fe₂O₃ particles.
 18. A system for sequestering carbon dioxide, said system comprising: a mineral and waste carbonation module for producing iron-based sorbents and carbonate forming material from at least one of minerals and industrial wastes using pH swing processes and sequestering carbon dioxide using the carbonate forming material; and a chemical looping module, said chemical looping module configured to reduce said iron-based sorbents and generate carbon dioxide for consumption in the mineral and waste carbonation module and regenerating said iron-based sorbents that have been reduced via oxidation with steam.
 19. The system according to claim 18, wherein minerals include magnesium and calcium-bearing minerals including iron and industrial wastes include magnesium and calcium-bearing wastes including steel slag and fly ash containing iron.
 20. The system according to claim 18, wherein said iron-based sorbents include Fe₂O₃.
 21. The system according to claim 18, wherein said pH swing processes include the use of at least one of acetic acid, citric acid, iminodiacetic acid, oxalic acid, phosphoric acid, gluconic acid, ascorbic acid, phthalic acid, a salt thereof, and a combination thereof as a chelating agent to facilitate the extraction of iron from said minerals.
 22. The system according to claim 18, wherein said chemical looping module further comprises: a fuel reactor for reducing said iron-based sorbents via a carbonaceous fuel to generate carbon dioxide; and a hydrogen production reactor for regenerating said iron-based sorbents that have been reduced via oxidation with steam to generate hydrogen.
 23. The system according to claim 18, further comprising a module for producing iron-based catalysts.
 24. The system according to claim 22, wherein said carbonaceous fuel includes gaseous fuels including synthetic gas (carbon monoxide and hydrogen) and methane, and solid fuels including coal, biomass, and municipal solid wastes. 